Substrate embedded time of flight sensor packaging

ABSTRACT

A method begins with forming a first wiring layer on a substrate, forming a cavity in the substrate, and laminating a bottom side of the substrate so as to cover a bottom side of the cavity. Next, an integrated circuit is placed within the cavity of the substrate, and then a first optically transparent layer is disposed on the top surface of the substrate to cover a top surface of the integrated circuit. The first optically transparent layer has an aperture formed therein exposing at least a portion of the top surface of the integrated circuit. A second wiring layer is disposed on a top surface of the first optically transparent layer in a pattern that does not obstruct light traveling to or from the top surface of the integrated circuit. The integrated circuit is a laser emitting integrated circuit or a reflected light detector.

RELATED APPLICATION

This application is a divisional application of U.S. application patent Ser. No. 15/172,548, filed Jun. 3, 2016, the contents of which are incorporated by reference to the maximum extent allowable under the law.

TECHNICAL FIELD

This disclosure relates to the field of time of flight ranging systems, and, more particularly, to electronic device packages containing time of flight ranging systems and associated methods of making those electronic device packages.

BACKGROUND

Time of flight ranging systems are now used in a variety of commercial and consumer products. A typical time of flight ranging system includes a ranging light emitter, such as a laser, that emits pulses of light. This light travels toward a target, and some of the light reflects off the target surface and returns to the time of flight ranging system where it is detected by a reflected light detector. Since the speed of light is known, by precisely measuring the elapsed time between emission of the light and detection of the reflected light, the distance between the time of flight ranging system and the target can be determined.

Particularly in the realm of consumer products, there is an ever present desire for miniaturization of components. Therefore, new developments in packaging arrangements and methods for building those packaging arrangements are desired for time of flight ranging systems.

SUMMARY

This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

Disclosed herein is an electronic device having a substrate, and an integrated circuit disposed within the substrate and having a top surface. The integrated circuit may be a laser emitting integrated circuit or a reflected light detector. A first interconnect layer is formed on the top surface of the substrate. A first optically transparent layer is formed on the top surface of the substrate and covering the top surface of the integrated circuit. A second interconnect layer is formed on a top surface of the first optically transparent layer. The second interconnect layer is patterned so as to not obstruct light traveling to or from the top surface of the integrated circuit through the first optically transparent layer.

Also disclosed herein is an electronic device having a substrate, with a laser emitting integrated circuit disposed within the substrate and having a top surface. A first interconnect layer is formed on a top surface of the substrate, and a first optically transparent layer formed on the top surface of the substrate and covering the top surface of the laser emitting integrated circuit. A second interconnect layer is formed on a top surface of the first optically transparent layer. The second interconnect layer is patterned so as to permit light emitted from the top surface of the laser emitting integrated circuit to pass through the first optically transparent layer and exit the electronic device.

Another electronic device disclosed herein includes a substrate, with a reflected light detector disposed within the substrate and having a top surface. A first interconnect layer is formed on the top surface of the substrate, and a first optically transparent layer is formed on a top surface of the substrate and covering the top surface of the reflected light detector. A second interconnect layer is formed on a top surface of the first optically transparent layer. The second interconnect layer is patterned so as to permit light to pass through the first optically transparent layer and reach the reflected light detector.

Also disclosed herein is a method of making the electronic device. The method includes forming a first interconnect layer on a substrate, and forming a cavity in the substrate. A bottom side of the substrate is laminated so as to cover a bottom side of the cavity, and an integrated circuit is placed within the cavity of the substrate. A first optically transparent layer is disposed on the top surface of the substrate and covering a top surface of the integrated circuit. A second interconnect layer is disposed on a top surface of the first optically transparent layer in a pattern that does not obstruct light traveling to or from the top surface of the integrated circuit. The integrated circuit is a laser emitting integrated circuit or a reflected light detector.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure where either a VCSEL or time of flight sensor has terminals on a top side thereof and is packaged within a substrate.

FIG. 2 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure where both a VCSEL and a time of flight sensor is packaged within a substrate.

FIG. 3 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure where either a VCSEL or time of flight sensor has terminals on top and bottom sides thereof and is packaged within a substrate.

FIG. 4 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure with either a VCSEL or time of flight sensor similar to that of FIG. 1 but where the first optically transparent layer has been thinned adjacent a top surface of the VCSEL or time of flight sensor.

FIG. 5 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure with either a VCSEL or time of flight sensor similar to that of FIG. 1 but where the first optically transparent layer has been removed adjacent a top surface of the VCSEL or time of flight sensor.

FIG. 6 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure with either a VCSEL or time of flight sensor similar to that of FIG. 1 but where a lens covers a portion of the top surface of the chip.

FIGS. 7-17 are a series of schematic cross sectional diagrams showing formation of the electronic device of FIG. 1.

FIG. 18 is a schematic cross sectional diagram of an electronic device in accordance with this disclosure similar to that of FIG. 1 but where a lens covers a portion of the top surface of the chip and is in turn covered by the first optically transparent layer.

DETAILED DESCRIPTION

The present description is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout, and elements separated in number by century are similar.

With initial reference to FIG. 1, an electronic device 100 is now described. The electronic device 100 includes a chip 110, such as one incorporating a vertical cavity surface emitting laser (VCSEL) diode or a time of flight sensor (such as a single photon avalanche diode), embedded within a substrate 102. In the case where the chip 110 includes a VCSEL diode, it emits laser light from its top surface, and in the case where the chip 110 includes a time of flight sensor, it senses light impinging upon its top surface. The chip 110 has terminals 112 a, 112 b extending from an upper surface thereof. The size of the chip may range from 0.8 mm×0.8 mm to 0.15 mm×0.15 mm, with a thickness ranging between 0.1 mm to 0.3 mm.

The substrate 102 may be comprised of any suitable substrate material, such as one meeting the known FR4 standards, and may have a size ranging from 5.0 mm×4.0 mm to 2.0 mm to 3.0 mm, with a thickness ranging between 400 μm to 300 μm.

Interconnect layer 104 is formed on the top surface of the substrate 102, while interconnect layer 106 is formed on the bottom surface of the substrate 102. The interconnect layers 104 and 106 may be constructed from copper or other suitable materials, with thicknesses on the order of 35 μm.

An optically transparent layer 114 is formed on the top surface of the substrate 102, covering the top surface of the chip 110 as well as the interconnect layer 104. The top surface of the optically transparent layer 114 is shown as even with the top surface of the terminals 112 a, 112 b of the chip 110, although in some instances may be uneven such that access to the terminals 112 a and 112 b is easily provided. Similarly, an optically transparent layer 118 is formed on the bottom surface of the substrate 102, covering the bottom surface of the chip 110 as well as the interconnect layer 106.

The optically transparent layers 114, 118 are to be transparent or permissive to the passing of light of the same optical wavelength of that emitted by, or detected by, the chip 110. One suitable material from which the optically transparent layers 114, 118 may be constructed from build-up film, such as ABF, although any suitable material may be used. The optically transparent layers 114, 118 may have a thickness on the order of 25 μm.

An interconnect layer 116 is formed on the top surface of the optically transparent layer 114, and an interconnect layer 120 is formed on the bottom surface of the optically transparent layer 118. The interconnect layers 116, 120 may be constructed from copper or other suitable materials, with thicknesses on the order of 40 μm.

Vias 197 may extend through the optically transparent layers 114 and 118 so as to respectively connect the interconnect layers 104 and 116, and 106 and 110.

Metallic coating layers 128 and 126 are respectively formed on the outer surfaces of the interconnect layers 116 and 120. The metallic coating layers 128, 126 may be constructed from NiAu and function to protect the exposed surfaces of the interconnect layer 116 and 128.

The use of the optically transparent layer 114, together with the patterning of the interconnect layers 104 and 116, permit the entry and exit of light into the chip 110, making the electronic device 100 usable and useful for performing time of flight ranging.

Other advantages of this design include a higher thermal stability due to the embedding of the chip 110, as well as electromagnetic shielding provided by the interconnect layers 104, 116 and 106, 120. In some applications, additional layers including different shielding structures may be included. Also, the use of interconnect layers instead of wire bonds may help to reduce generated or detected electromagnetic interference, to reduce impedances, and to permit direct connection to driver circuitry.

A variety of similar permutations of the design described above are within the scope of this disclosure. For example, as shown in FIG. 2, both a VCSEL 210 and time of flight sensor 211 may be embedded within the substrate 102. This permits the creation of a single package for use in a time of flight system. Moreover, it allows for producing of a device having connections to both the VCSEL 210 and time of flight sensor 211 that are at a same height even if the terminals of those components have different heights.

As shown in FIG. 3, the chip 310 need not have both of its terminals extending from its top surface, and may instead have one terminal 312 b extending from its top surface, while its other terminal 312 a extends from its bottom surface. In other applications, both terminals might extend from the bottom surface, or there may be any number of terminals, with each extending from either the top or bottom surface.

In some applications, perhaps due to the specific material used to construct the optically transparent layer 414 or due to the wavelength of the light to enter or exit the chip 110, the optically transparent layer 414 may have a reduced thickness adjacent a portion of the top surface of the chip 110. Such a situation is shown in FIG. 4. In yet another application, the optically transparent layer 514 may be completely removed adjacent a top portion of the top surface of the chip 110, such as shown in FIG. 5.

The electronic device 100 may be incorporated into a variety of structures and devices, and may have external components attached. For example, as shown in FIG. 6, a lens 675 may be attached to the top surface of the optically transparent layer 114 adjacent the top surface of the chip 110 so as to focus light entering or exiting the chip 110. Similarly, as shown in FIG. 18, a lens or transparent cap 676 may be attached to the top surface of the chip 110 but covered by the optically transparent layer 114.

Formation of the electronic device 100 will now be described with reference to the series shown in FIGS. 7-17. Initially, the substrate 102 is clad with copper layers 104 a and 106 a that will ultimately become interconnect layers (FIG. 7). Then, the copper layers 104 a and 106 a are patterned into suitable shapes so as to become interconnect layers 104 and 106 (FIG. 8). This patterning is performed via suitable processes, such as etching. In some applications, the copper layers 104 a and 106 a may instead be part of a film layer that is applied to the substrate 102.

Next, a cavity 101 is formed into the substrate 102 via suitable processes (FIG. 9). Thereafter, an adhesive layer 108 is laminated to the bottom surface of the substrate 102 so as to close off the bottom side of the cavity 101 formed in the substrate 102 (FIG. 10). Then, the chip 110 is placed into the cavity 101 (FIG. 11).

Then, a sheet of optically transparent material 114, with pre-formed copper cladding 116 thereon is laid on top of the chip 110, interconnect layer 104, and substrate 102 and pressed into place (FIG. 12). Laser drilling and copper plating is then used to connect the terminals 112 b, 112 b to the copper cladding 116 (FIG. 13).

At least a portion of the adhesive layer 108 is then removed, and another sheet of optically transparent material 118 is placed adjacent the bottom surface of the chip 110, interconnect layer 106, and substrate 102, and pressed into place (FIG. 13, FIG. 14). The sheet of optically transparent material 118 has pre-formed copper cladding 120 therein.

Thereafter, the copper layers 116 and 120 are etched (FIG. 15), and etching is performed so as to pattern them into the desired interconnect layers (FIG. 16). At this point, if desired, portions of the optically transparent material 114 adjacent the top surface of the chip 110 may be removed.

Then, photo resist layers 103 and 105 are respectively patterned over the outer surfaces of the optically transparent layers 114 and 118 (FIG. 17), and then the protective layers 128 and 126 are formed via plating (shown in FIG. 1).

The formation of the electronic device 100 using the techniques described above provide for a high yield and low cost of manufacture. These techniques allow for the formation of an electronic device 100 in which the die size is up to 40% the size of the substrate.

Many modifications and other embodiments will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that various modifications and embodiments are intended to be included within the scope of the appended claims. 

1. A method, comprising: forming a first wiring layer on a substrate; forming a cavity in the substrate; laminating a bottom side of the substrate so as to cover a bottom side of the cavity; placing an integrated circuit within the cavity of the substrate, wherein the integrated circuit comprises one of a laser emitting integrated circuit and a reflected light detector; disposing a first optically transparent layer on the top surface of the substrate and which covers a top surface of the integrated circuit, wherein the first optically transparent layer has an aperture formed therein exposing at least a portion of the top surface of the integrated circuit; and disposing a second wiring layer on a top surface of the first optically transparent layer in a pattern that does not obstruct light traveling to or from the top surface of the integrated circuit.
 2. The method of claim 1, further comprising removing a portion of the first optically transparent layer so as to reduce a thickness thereof adjacent the top surface of the integrated circuit.
 3. The method of claim 1, further comprising removing a portion of the first optically transparent layer so as to expose a portion of the top surface of the integrated circuit.
 4. The method of claim 1, wherein disposing the first optically transparent layer and disposing the second wiring layer comprises placing a sheet of optically transparent material clad with the second wiring layer on the top surface of the substrate which covers the top surface of the integrated circuit.
 5. The method of claim 1, further comprising placing a transparent cap over a top surface of the second wiring layer and the first optically transparent layer.
 6. The method of claim 5, wherein the transparent cap comprises a lens.
 7. The method of claim 1, further comprising placing a transparent cap over a top surface of the integrated circuit, wherein the transparent cap has a top surface covered by the first optically transparent layer.
 8. The method of claim 1, further comprising: forming a third wiring layer on a bottom surface of the substrate; and placing a sheet of optically transparent material clad with a fourth wiring layer on a bottom surface of the substrate which covers the third wiring layer.
 9. A method, comprising: forming a first wiring layer on a substrate; forming a cavity in the substrate; laminating a bottom side of the substrate so as to cover a bottom side of the cavity; placing an integrated circuit within the cavity of the substrate, wherein the integrated circuit comprises one of a laser emitting integrated circuit and a reflected light detector; disposing a first optically transparent layer on the top surface of the substrate which covers a top surface of the integrated circuit, wherein the first optically transparent layer has a reduced thickness portion adjacent the top surface of the integrated circuit; disposing a second wiring layer on a top surface of the first optically transparent layer in a pattern that does not obstruct light traveling to or from the top surface of the integrated circuit.
 10. The method of claim 9, further comprising disposing a transparent cap over a top surface of the second wiring layer and the first optically transparent layer.
 11. The method of claim 9, further comprising disposing a lens over a top surface of the second wiring layer and the first optically transparent layer.
 12. The method of claim 9, further comprising disposing a transparent cap over a top surface of the integrated circuit, the transparent cap having a top surface covered by the first optically transparent layer.
 13. The method of claim 9, wherein the integrated circuit comprises a laser emitting integrated circuit configured to emit laser light from the top surface thereof, with the emitted laser light having a given wavelength; and wherein the first optically transparent layer is optically transparent to light having the given wavelength.
 14. An electronic device, comprising: a substrate; a reflected light detector disposed within the substrate and having a top surface; a first wiring layer formed on the top surface of the substrate; a first optically transparent layer formed on the top surface of the substrate and covering the top surface of the reflected light detector, wherein the first optically transparent layer has an aperture formed therein exposing at least a portion of the top surface of the reflected light detector; a second wiring layer formed on a top surface of the first optically transparent layer; wherein the second wiring layer is patterned so as to permit light to pass through the first optically transparent layer and reach the reflected light detector.
 15. The electronic device of claim 14, further comprising a transparent cap disposed over a top surface of the second wiring layer and the first optically transparent layer.
 16. The electronic device of claim 14, further comprising a transparent cap disposed over a top surface of the reflected light detector and having a top surface covered by the first optically transparent layer. 